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Xj to sporty muffler swap?

Discussion in 'XJ Technical Chat' started by Rebecca Proppe, Jan 8, 2024.

  1. Rebecca Proppe

    Rebecca Proppe New Member

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    Hi all! Everyone here has been so helpful in the past so I thought I would take a stab at it again.

    My '82 750 maxim was hit HARD in my underground parking while I was away for the holidays. So hard that the muffler was split in half from hitting the center stand (among other damage).

    I saw some old threads on here saying that I can actually replace the muffler for a Harley sportster variety without needed to rejet? However the threads are all pretty old and mostly focus on replacing the entire exhaust system. My question is, is there a specific type of size of sportster muffler that will fit our bikes? Has anyone else here also just swapper out the muffler and not the entire exhaust? Tbh I am mostly motivated to do the Harley swap not only because some folks on here said it's easy, but that it also sounds great. I am looking at a few options on eBay like this: ttps://www.ebay.ca/itm/315035701403?epid=1924681407&hash=item495997509b:g:F4wAAOSwN1xlfhC-&amdata=enc%3AAQAIAAAA8HP%2Biqm0XSjug4rN62ATHPCTjWxkVd3aZgY14KMlWeyyG6Jg5YHNy%2BxDzoyxkGYJm%2FbtZIVO%2B4PczA26BNTk0XPZkK2Wz0rwwsiddufGU%2Fo5PIwKbkB9Y1Ze813nhU9De9s6k0kyzkraNvqDGJBArvpxBLYd5Swzdrv5TmS%2BBlUrnLOlkHWpqWD5I9C%2F4HJd0HEN6pcATZyvYTranaBD%2BFUVODNwsSYybcffq5nvChBu1cNrKkaTJlxKQGszg7Fmed97NBKYrD59srjDLZUXIFhla%2BFxZlc9wzBq0E4AzvPgy2rs3GubIsPtvWWJB2Oweg%3D%3D%7Ctkp%3ABk9SR-S4gc-cYw )

    I haven't done any fiddling with my bike since the damage occured since I'm still waiting for insurance to come asses, so I thought I'd take it to you guys. Thanks in advance! :)
     
  2. Melnic

    Melnic Active Member

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    Interesting question.
    I had a 2007 Sportster which is soft mounted (they started that in 2004) and Fuel injected (started in 2007)
    The mufflers have a cross pipe (to connect the 2 mufflers together to help with flow) That is at the beginning of the muffler.
    The XJ650 I have does the cross pipe stuff under the bike just before it splits to each side where you would be welding this muffler to.
    If you look at pics of a 2002 sportster, you will see the cross pipe on the side of the engine up high.
    2004 im looking at pics and you don't see the cross pipe. If you were to see videos of installing slip ons for a 04-13 harley, you will see the black cross pipe and where they put the crush gasket.

    You would need to plug that up.
    I actually have those V&H slip ons at home cause I sold the bike with stock mufflers attached. I thought about what you are asking The mufflers have an angle on the back end cause they BOTH mount on the right side.

    Not sure about the pipe diameters either. I wonder if anyone has ever cut the XJ pipes to make a slip on?
    Some work to make a mounting adaptor bracket would be needed.

    With an XJ that has dual exhaust on each side, that kind of negates that as an option.
    I"m wondering if Pre 2003 stock exausts would work or not. Those are going to be plentiful and CHEAP. The mounting point is one up and one down, so when you flip it to the left side of the bike, you may be able to make it work. Plus the ends are round and not angled
    Something like this
    https://www.ebay.com/itm/256281068853
     
  3. Dan Gardner

    Dan Gardner Well-Known Member Premium Member

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    That really sucks @Rebecca Proppe

    sorry to hear that

    I know it’s not what you’re asking for, but I hope to one day fit a Marving system on a 750. Just my $.02

    of course I understand the Marving is not cheap. That’s why it’s on my someday list
     
    Jetfixer likes this.
  4. Dave in Ireland

    Dave in Ireland Well-Known Member

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    I got a pair of Dyna mufflers as offtakes from by an upgrading owner. Not enough noise from the factory mufflers, the usual case.
    The fitted nicely on to the XJ outlets, but I had to use a spacing collar to take up the diam difference from the outlet of the XJ to the HD inlets. I just used the fronts of the old XJ mufflers, cut off a couple inches and put them into service as spacers.
    One thing, because the Dynas are staggered the internal baffling is different between them, so I had to change them to make the baffling be the same length from the input end of the mufflers to even up both sides of the XJ.
    It worked well enough - breathed well, wasn't much louder than stock.
    From what I read, the Sportser mufflers might work better, and not need the adjustment of the baffle positions.
     
    Jetfixer likes this.
  5. Melnic

    Melnic Active Member

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    HD Softail muffler on XJ650 video
     
    Jetfixer likes this.
  6. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    the 750 maxim is easy.... just loosen the bolt where the muffler clamps onto the collector-box outlet, remove the bolt that hold the muffler up to the passenger foot-peg bracket, now twist, rotate, do circles, yank, whatever you need to to get the muffler to slide off. There is a gasket between the muffler inlet and the collector-box outlet—- if it’s rusty, the can be a bear. One it’s off, slide the sporty muffler on and tighten up. Be creative with a support for the back of the muffler. Repeat for the other side
     
    Colin 85 700 and k-moe like this.
  7. Rebecca Proppe

    Rebecca Proppe New Member

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    Amazing, thank you guys so much for your advice! Unfortunately looks like there's more damage than I saw initially so I'm having a mechanic actually look at it for insurance. Fingers crossed i can just do the swap myself in the spring anyways ahahah thanks for all the advice!!!
     

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